Modular habitable structures, and associated systems and methods

ABSTRACT

A module for a structural system may include chords oriented along a length of the module and a plurality of rib assemblies positioned between the chords. Two of the rib assemblies may include shear keys configured to be received in piers at a final installation site. A method of making a structure may include positioning the shear keys in pockets of the piers.

BACKGROUND

Conventional building construction typically involves site-specificdesigns that are constructed entirely or nearly entirely on-site. Thereis a desire for modular building designs that can be assembled at aremote site and brought to a building site for assembly in variousconfigurations that can be repeated or altered among various sites.

SUMMARY

Representative embodiments of the present technology include astructural system including one or more modules. A module may include afirst upper chord oriented along a length of the module, a first lowerchord oriented along the length of the module, a second upper chordpositioned opposite the first upper chord, parallel to the first upperchord, a second lower chord positioned opposite the first lower chord,parallel to the first lower chord, and a plurality of rib assembliespositioned between the first upper chord, the first lower chord, thesecond upper chord, and the second lower chord, the rib assembliesextending along a width of the module perpendicular to the chords. Atleast one of the chords may include a plurality of chord portions joinedtogether with one or more connector plates. Two of the rib assembliesmay include shear keys configured to be received in support structures,such as piers at a final installation site. In some embodiments, eachchord portion includes a plurality of arrays of holes. The ribassemblies may include two vertical column beams and two or morehorizontal crossbeams connecting the column beams to each other. Theshear keys may project downwardly from the vertical column beams.

Another representative embodiment of the present technology includes amethod of making a structure. Making the structure may include making amodule of the structure. The method may be at least partially performedat a first location (such as a factory) that is remote from a secondlocation (such as a final outdoor installation location of thestructure). The method may include positioning shear keys (attached tothe module) into pockets formed in piers (such as concrete piers) at thefinal installation location. The method may include leveling the moduleby positioning shims in the pockets under the shear keys or moving theshear keys within the pockets. Empty space in the pockets may be filledwith filler material, eliminating a need for bolting the module to thepiers.

Other features and advantages will appear hereinafter. The featuresdescribed above can be used separately or together, or in variouscombinations of one or more of them.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein the same reference number indicates the sameelement throughout the several views:

FIG. 1 illustrates a perspective view of a modular structure configuredin accordance with embodiments of the present technology.

FIG. 2 illustrates a perspective view of a module configured inaccordance with embodiments of the present technology and suitable foruse in the modular structure shown in FIG. 1 .

FIG. 3 illustrates a side perspective view of a chord portion configuredin accordance with embodiments of the present technology and suitablefor implementation in the module shown in FIG. 2 .

FIG. 4 illustrates a chord configured in accordance with embodiments ofthe present technology and suitable for implementation in the moduleshown in FIG. 2 .

FIG. 5 a illustrates a rib assembly configured in accordance withembodiments of the present technology and suitable for implementation inthe module shown in FIG. 2 .

FIG. 5 b illustrates another rib assembly configured in accordance withembodiments of the present technology and suitable for implementation inthe module shown in FIG. 2 .

FIG. 6 illustrates positioning a module on a pier at a finalinstallation site, in accordance with embodiments of the presenttechnology.

DETAILED DESCRIPTION

The present technology is directed to modular structures (which may behabitable structures), and associated systems and methods. Variousembodiments of the technology will now be described. The followingdescription provides specific details for a thorough understanding andenabling description of these embodiments. One skilled in the art willunderstand, however, that the invention may be practiced without many ofthese details. Additionally, some well-known structures or functions maynot be shown or described in detail so as to avoid unnecessarilyobscuring the relevant description of the various embodiments.Accordingly, embodiments of the present technology may includeadditional elements or exclude some of the elements described below withreference to FIGS. 1-6 , which illustrate examples of the technology.

The terminology used in this description is intended to be interpretedin its broadest reasonable manner, even though it is being used inconjunction with a detailed description of certain specific embodimentsof the invention. Certain terms may even be emphasized below; however,any terminology intended to be interpreted in any restricted manner willbe overtly and specifically defined as such in this detailed descriptionsection.

Where the context permits, singular or plural terms may also include theplural or singular term, respectively. Moreover, unless the word “or” isexpressly limited to mean only a single item exclusive from the otheritems in a list of two or more items, then the use of “or” in such alist is to be interpreted as including (a) any single item in the list,(b) all the items in the list, or (c) any combination of items in thelist. Further, unless otherwise specified, terms such as “attached” or“connected” are intended to include integral connections, as well asconnections between physically separate components.

As used herein, the term “and/or” when used in the phrase “A and/or B”means “A, or B, or both A and B.” A similar manner of interpretationapplies to the term “and/or” when used in a list of more than two terms.

FIG. 1 illustrates a perspective view of a modular structure 100configured in accordance with embodiments of the present technology. Themodular structure 100 may be a habitable structure such as a home or anoffice, or it may be a structure for storage or other non-habitablepurposes. The modular structure 100 may be supported on a plurality ofpiers 110 or other suitable support structures. In some embodiments, themodular structure 100 can include one or more modules 120. FIG. 1illustrates two modules 120 joined together at an interface 130.

Each module 120 includes usable or habitable interior space, and whenmultiple modules 120 are joined, they may form a combined interiorspace. Supporting the modules 120 on piers 110 enables building themodular structure 100 on uneven terrain while controlling (e.g.,minimizing) the impact on the surrounding environment. Supporting themodules 120 on piers 110 may also facilitate using the space beneath themodular structure 100 for storage, additional usable space, or otheruses. In coastal areas or other areas prone to flooding, the piers 110provide elevation above floodwaters. Although FIG. 1 shows one exampleof modules 120 positioned adjacent to each other to form the modularstructure 100, in other embodiments, the modules 120 may be positionedor arranged to form other shapes or configurations of modular structures100 (i.e., any arrangement or quantity of modules 120 abutting orconnected to each other).

FIG. 2 illustrates a perspective view of a module 120 configured inaccordance with embodiments of the present technology and suitable foruse in the modular structure 100 shown in FIG. 1 . In some embodiments,the module 120 may be rectilinear, with rectilinear components. Forexample, in some embodiments, the module 120 may include a Vierendeeltruss structure. In some embodiments, four piers 110 may support themodule 120. In some embodiments, the piers 110 may be positionedapproximately 12 feet from ends of the module 120 along the length L ofthe module 120, and the piers 110 may be positioned approximately 48feet apart along the length L of the module 120, such that the overallmodule 120 may be approximately 72 feet long. The piers 110 may bepositioned approximately 18 feet apart along the width W of the module120, such that the overall module 120 may be approximately 18 feet inwidth. Other embodiments may include other suitable dimensions, otherquantities of piers 110, or other support structures.

The module 120 may include a plurality of chords 200 (such as fourchords 200), which may span the length L of the module 120. For example,in some embodiments, the chords 200 may include a first upper chord 202oriented along the length L of the module, a first lower chord 204oriented along the length L of the module, a second upper chord 206positioned opposite the first upper chord 202 and oriented parallel tothe first upper chord 202, and a second lower chord 208 positionedopposite the first lower chord 204 and oriented parallel to the firstlower chord 204.

The module 120 may also include a plurality of rib assemblies 210, eachof which extends along the width W of the module 120 between the chords200. The module 120 may further include suitable roof panels 220 andfloor panels 230. The roof panels 220 and the floor panels 230 may besupported by the rib assemblies 210 and/or the chords 200. FIG. 2 showstwo roof panels 220 and two floor panels 230, although more or fewerroof panels 220 and/or floor panels 230 may be included in the module120. For example, the entirety of the top of the module 120 may includeroof panels 220, and the entirety of the bottom of the module 120 mayinclude floor panels 230. The module 120 may also include one or morewalls or windows 240, which may also be supported by the rib assemblies210 and the chords 200.

One or more of the chords 200 may be formed as a single integral beam orwith a plurality of chord portions 250 joined together with one or moreconnector plates 260. For example, FIG. 3 illustrates a side perspectiveview of a chord portion 250 configured in accordance with embodiments ofthe present technology and suitable for implementation in the module120. The chord portion 250 may be an I-beam, a C-beam, a box beam, oranother suitable linear extrusion. FIG. 4 illustrates a perspective viewof a chord 200 configured in accordance with embodiments of the presenttechnology. The chord 200 may include two or more chord portions 250 a,250 b joined together with a connector plate 260.

Referring to FIGS. 3 and 4 , the chord portion 250 may include fasteninginterfaces in the form of holes 300 that are arranged in arrays 310(only some of the holes 300 are labeled in FIGS. 3 and 4 to avoidobscuring the figures). The connector plate 260 includes one or morearrays 310 of holes 300 corresponding to one of the arrays of holes on afirst chord portion 250 a and one of the arrays of holes on a secondchord portion 250 b. Suitable fasteners 320, such as bolts, may beinstalled in corresponding holes 300 to hold the chord portions 250together with the connector plate 260.

In some embodiments, the connector plate 260 carries the load from onechord portion 250 a to the other chord portion 250 b. Although aconnector plate 260 is shown and described for connecting the chordportions 250, in some embodiments, a beam with holes similar to theholes 300 in the connector plate 260 may be used to join the chordportions 250. In some embodiments, an overall length L1 of one or morechord portions 250 may be approximately 405 inches, or other suitabledimensions.

FIG. 5 a illustrates a bottom perspective view of a rib assembly 500configured in accordance with embodiments of the present technology andsuitable for implementation as one or more of the rib assemblies 210described above with regard to FIG. 2 . In some embodiments, the ribassembly 500 is a rectilinear structure that includes two verticalcolumn beams 510 each forming a side of the rib assembly 500, and two ormore horizontal crossbeams 520 connecting the column beams 510 to eachother, such as one or more upper horizontal crossbeams 520 a and one ormore lower horizontal crossbeams 520 b. In some embodiments, eachhorizontal crossbeam 520 may be bolted to each column beam 510. In otherembodiments, the horizontal crossbeams 520 may be welded to the columnbeams 510, or they may be attached in other suitable ways. In someembodiments, the rib assembly 500 may include two upper horizontalcrossbeams 520 a connected with one or more upper tie plates 525, andtwo lower horizontal crossbeams 520 b connected with one or more lowertie plates 527. The upper and lower tie plates 525, 527 enhance thesquareness and rigidity of the rib assembly 500.

In some embodiments, the rib assembly 500 may include one or more shearkeys 530 (such as two shear keys 530, or one on each side of the ribassembly 500). The shear keys 530 may be bolted and/or welded into therib assembly 500. The shear keys 530 project downwardly from the ribassembly 500 and are configured to engage the piers 110 (see FIGS. 1 and2 ), as explained in additional detail below with regard to FIG. 6 .

FIG. 5 b illustrates a rib assembly 540 configured in accordance withembodiments of the present technology and suitable for implementation asone or more of the rib assemblies 210 described above with regard toFIG. 2 . The rib assembly 540 may be identical to, or generally similarto, the rib assembly 500 described above with regard to FIG. 5 a ,except that it may not include the shear keys 530. Each of the ribassemblies 210, 500, 540 may be attached to the chords 200 or chordportions 250 via suitable fasteners (such as bolts, screws, or othersuitable fasteners) or via welding, or via another suitable attachment.

With additional reference to FIG. 2 , in some embodiments, a module 120may be supported on only four piers 110 (or another suitable number ofpiers 110). A module 120 may include a number of shear keys 530corresponding to the number of piers 110 (for example, four shear keys530 for four piers 110). Accordingly, in some embodiments, a module 120may include two of the rib assemblies 500 with shear keys 530, with theremainder of the rib assemblies 210 being the rib assemblies 540(without shear keys 530). The rib assemblies 210, 500, 540 may includemore or fewer features or may take other forms, in other embodiments.

With continued reference to FIG. 2 , the module 120 may further includefinishing elements that make it more habitable, such as plumbing,electrical facilities, interior bulkheads or walls to create roomspaces, and other finishing elements. In some embodiments, finishingaspects such as flooring, roofing, windows, doors, wiring, plumbing,furnishings, or other aspects may be added to the module 120 in afactory or other site remote from the final installation site. In otherembodiments, the module 120 may be moved to a final installation site asa skeletal frame, and finishing aspects may be added at the finalinstallation site. Beams and columns forming the module 120 may beformed with any suitable material, such as steel, aluminum, or anothersuitable metal material.

FIG. 6 illustrates positioning a module 120 on a pier 110 at a finalinstallation site, in accordance with embodiments of the presenttechnology. The piers 110 may be concrete, and therefore may be subjectto their own inaccuracies in location. Embodiments of the presenttechnology compensate for the high tolerances associated with the piers110. For example, in some embodiments, each pier 110 may include apocket 600 for receiving a shear key 530. In some embodiments, thepocket 600 may be wider than the shear key 530 to facilitate adjustmentof the position of the module 120 at the installation site (e.g., bymoving the shear keys 530 within the pockets 600).

In some embodiments, the system may include a shim 610 positionedbetween the shear key 530 and the bottom 620 of the pocket 600. The shim610 facilitates leveling and height adjustment to compensate forinaccuracies and/or high tolerances in the pier 110 and/or the pocket600. Although shims 610 may not be needed if the piers 110 and pockets600 are positioned with sufficient accuracy, in some embodiments, shims610 of different sizes may be used in each pier 110. When the module 120is positioned and leveled at the final installation site, fillermaterial (such as concrete and/or grout material) may be positioned inany empty space surrounding or adjacent to the shear key 530 within thepocket 600. In some embodiments, all the empty space surrounding theshear key 530 within the pocket 600 may be filled with filler material.Accordingly, in some embodiments, anchor bolts are not needed to mountthe module 120 to the piers 110.

A method of making a modular structure in accordance with embodiments ofthe present technology may include building the chords 200 (such as thechords 202, 204, 206, 208) and the rib assemblies 210, then connectingthe elements together, then moving the assembly to a final installationsite, and then penetrating/positioning the shear keys 530 into the piers110. Optionally, the method may include leveling the module 120 usingone or more shims 610 and adjusting the position of the module 120 bymoving the module 120 relative to the piers 110 (which may includemoving the shear keys 530 side to side within the pockets 600).

Optionally, in some embodiments, other/additional modules 120 may bepositioned adjacent to the module 120 on their own piers 110. Themodules 120 may be positioned and aligned relative to one another,facilitated by moving the shear keys 530 in the open space of the pocket600 and/or by positioning one or more shims 610 under the shear keys 530in the pockets 600. In some embodiments, methods may include filling theopen space in the pockets 600 with grout, concrete, or other suitablefiller material to lock modules 120 in position. Other finishing workmay be performed at any suitable time, such as attachment orinstallation of components that render the module 120 habitable,including flooring, roofing, electrical, plumbing, and other components.In some embodiments, part of the assembly process may be performed in afactory, including some of finishing work, such as attaching roof orfloor panels, electric, plumbing, etc. The modular nature of theassemblies facilitates repeatable and easily duplicated manufacturingand installation of these components.

Aspects of the embodiments of the present technology provide severaladvantages. For example, embodiments of the present technology provideknown repeatable structures, which enables subsequent finishing tradeslike mechanical, plumbing, glazing, trim, electrical, etc. to rapidlyadd their parts with less custom fabrication. In some embodiments,construction of modules 120 configured in accordance with embodiments ofthe present technology may not involve any welding at the finalinstallation site (all welding may be performed at the prefabricationsite/factory).

From the foregoing, it will be appreciated that specific embodiments ofthe presently disclosed technology have been described herein forpurposes of illustration, but that various modifications may be madewithout deviating from the scope of the technology. For example, stepsof the methods described herein may be performed in different orders orat different times, or concurrently. Accordingly, modules 120 andmodular structures 100 configured in accordance with embodiments of thepresent technology may include other combinations of features disclosedherein.

Certain aspects of the technology described in the context of particularembodiments may be combined or eliminated in other embodiments. Further,while advantages associated with certain embodiments of the presentlydisclosed technology have been described in the context of thoseembodiments, other embodiments may also exhibit such advantages, and notall embodiments need necessarily exhibit such advantages to fall withinthe scope of the technology. Accordingly, the disclosure and associatedtechnology can encompass other embodiments not expressly shown ordescribed herein.

What is claimed is:
 1. A structural system comprising a module, themodule comprising: a first upper chord oriented along a length of themodule; a first lower chord oriented along the length of the module; asecond upper chord positioned opposite the first upper chord, parallelto the first upper chord; a second lower chord positioned opposite thefirst lower chord, parallel to the first lower chord; and a plurality ofrib assemblies positioned between the first upper chord, the first lowerchord, the second upper chord, and the second lower chord, the ribassemblies extending along a width of the module perpendicular to thechords; wherein at least one of the chords comprises a plurality ofchord portions joined together with one or more connector plates; andwherein two rib assemblies of the plurality of rib assemblies eachcomprises two shear keys configured to be received in supportstructures.
 2. The system of claim 1, wherein each of the rib assembliescomprises two vertical column beams and two or more horizontalcrossbeams connecting the column beams to each other.
 3. The system ofclaim 2, wherein the shear keys are attached to the vertical columnbeams of the two rib assemblies, wherein the shear keys projectdownwardly from the vertical column beams of the two rib assemblies. 4.The system of claim 1, wherein the support structures comprise fourconcrete piers, wherein the shear keys are positioned in the concretepiers.
 5. The system of claim 1, wherein the module is a first module,and wherein the system comprises a second module joined to the firstmodule at an interface.
 6. The system of claim 1, wherein the module isa Vierendeel truss structure.
 7. The system of claim 1, wherein themodule further comprises roof panels and floor panels supported by theplurality of rib assemblies or by the chords.
 8. A method of making astructure, the method comprising: at a first location, making a moduleof the structure, wherein making the module comprises attaching aplurality of rib assemblies to a plurality of chords, wherein attachingthe plurality of rib assemblies comprises attaching the rib assembliesperpendicular to the chords, and wherein two rib assemblies of theplurality of rib assemblies each comprise two shear keys configured tobe received in support structures at a second location that is differentfrom the first location; transporting the module to the second location;at the second location, building a plurality of concrete piers, whereinbuilding the concrete piers comprises forming a pocket in each of theconcrete piers; and at the second location, positioning the module onthe concrete piers, wherein positioning the module on the concrete pierscomprises positioning the shear keys in the pockets.
 9. The method ofclaim 8, further comprising attaching roof and floor panels to themodule at the first location.
 10. The method of claim 8, furthercomprising: positioning a shim beneath one or more of the shear keyswithin the pocket to level the module; and after positioning the shearkeys in the pockets, positioning a filler material in empty spaceadjacent to the shear keys within the pockets.
 11. The method of claim8, wherein the module is a first module, the method further comprisingmaking a second module and positioning the second module adjacent to thefirst module and leveling the second module relative to the firstmodule.